Carel heaterSteam UR Series User manual

High Efficiency Solutions

heaterSteam - UR

NO POWER

& SIGNAL

CABLES

TOGETHER

READ CAREFULLY IN THE TEXT!

Electric resistance humidiﬁ er

User manual

3

ENG

“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

WARNINGS

The humidi ers manufactured by CAREL Industries are advanced products,

whose operation is speci ed in the technical documentation supplied with

the product that can be downloaded, even prior to purchase, from the

website www.carel.com. Every product made by CAREL Industried, in relation

to its advanced level of technology, requires a quali cation/ con guration /

setup phse in order to best ful l your speci c application. The lack of such

phase of study, as indicated in the manual, can cause the  nal product to

malfunction, of which CAREL Industries cannot be held responsible. The

client (builder, developer or installer of the  nal equipment) assumes all

responsibility and risk relating to the con guration of the product in order to

achieve the expected results in relation to the speci c  nal installation and/

or equipping. In this case, subject to speci c agreements, CAREL Industries

acts as a consultant for the success of the installation / start-up / use of the

machine, but in no case does it accept liability for proper operation of the

humidi er and of the  nal plant, should the warnings and recommendations

in this manual or in any other technical documentation of the product not

be followed. In particular, in addition to the obligation to observe the above

mentioned warnings and recommendations for proper use of the product, we

recommend paying attention to the following warnings:

DANGER ELECTRIC SHOCK: The humidi er includes live electrical parts.

Disconnect the power supply before accessing internal parts, in case of

maintenance and during installation.

DANGER WATER LEAKS: The humidi er automatically and constantly  lls/

drains quantities of water. Malfunctions in the connections or humidi er may

cause leaks.

DANGER OF BURNS: The humidi er contains hot parts and delivers steam

at 100 °C / 212 °F.

• The product is designed exclusively to humidify rooms either directly or

through distribution systems (ducts).

• Installation, operation and maintenance must be performed by quali ed

personnel, aware of the necessary precautions and able to perform the

required operations correctly.

• All operations on the product must be carried out according to the

instructions given in this manual and on the labels applied to the

product. Any uses or modi cations unauthorized by the manufacturer are

considered improper. CAREL Industries denies all responsibility for such

unauthorized uses.

• Do not attempt to open the humidi er in any way other than the ones

described in the manual.

• Follow all local regulations while installing the humidi er.

• Keep the humidi er out of the reach of children and pets.

• Do not install and use the product near objects that can be damaged

by contact with water (or condensate). CAREL Industries denies all

responsibility for direct or indirect damage as a result of loss of water from

the humidi er.

• Do not use corrosive chemicals, aggressive solvents or detergents to clean

the internal or external parts of the humidi er, unless speci cally indicated

in the user’s manual.

CAREL Industries adopts a continuous development policy. Therefore, CAREL

reserves the right to carry out modi cations and improvements to any

product described in this document without prior notice. The technical data

in the manual can undergo modi cations without forewarning. The liability

of CAREL Industries in relation to its own product is governed by CAREL

Industries general contract conditions published on the website www.carel.

com and/or by speci c agreements with clients; in particular, within the limits

set by the applicable law, in no way will CAREL Industries, its employees or

its branch o ces/a liates be responsible for any lack of earnings or sales,

loss of data and information, cost of replacement goods or services, damage

to objects or persons, work interruptions, or any direct, indirect, accidental,

patrimonial, coverage, punitive, special or consequential damage in any way

caused, be they contractual, out-of-contract, or due to negligence or other

responsibility originating from the installation, use or inability of use of the

product, even if CAREL Industries or its branch o ces/a liates have been

warned of the possible damage.

ATTENTION

NO POWER

& SIGNAL

CABLES

TOGETHER

READ CAREFULLY IN THE TEXT!

Separate the probe cables and the digital input cables as much as possible

from the inductive load and power cables to prevent possible electro-

magnetic interference.

Never introduce power cables and signal cables (including those of electric

control board) into the same cable troughs.

The installation of the product must absolutely include the grounding

connection, using the special yellow-green terminal on the terminal block.

Do not use the neutral as grounding connection.

DISPOSAL

The humidi er consists of metal parts and plastic parts. With reference to the

European Parliament and Council Directive 2002/96/EC issued on 27 January

2003 and the related national implementation legislation, please note that:

1. WEEE cannot be disposed of as municipal waste, said waste must be

collected separately;

2. the public or private waste collection systems de ned by local legislation

must be used.

3. the equipment may contain hazardous substances: the improper use or

incorrect disposal of such may have negative e ects on human health

and on the environment;

4. the symbol (crossed-out wheeley bin) shown on the product or on the

packaging and on the instruction sheet indicates that the equipment has

been introduced onto the market after 13 August 2005 and that it must

be disposed of separately;

5. in the event of illegal disposal of electrical and electronic waste, the

penalties are speci ed by local waste disposal legislation.

Warranty for materials: 2 years (from the manufacture date, excluding

consumables).

Certi cation: the quality and safety of CAREL products are guaranteed by

CAREL’s ISO 9001 certi ed design and production system, as well as

marking.

5

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

Content

1. INTRODUCTION AND INSTALLATION 7

1.1 HeaterSteam (UR*)......................................................................................................7

1.2 Dimensions and weights ........................................................................................7

1.3 When opening the packaging ............................................................................7

1.4 Positioning .......................................................................................................................7

1.5 Wall mounting ..............................................................................................................7

1.6 Removing the front panel......................................................................................8

1.7 Mounting the front panel ......................................................................................8

1.8 Material supplied with the appliance .............................................................9

1.9 Technical data plate ...................................................................................................9

1.10 Hydraulic circuit ...........................................................................................................9

1.11 Structure of models UR002 – UR0013 .........................................................10

1.12 Structure of models UR020 – UR0080 .........................................................11

2. HYDRAULIC CONNECTIONS 12

2.1 Supply water ..............................................................................................................14

2.2 Drain water ...................................................................................................................14

3. STEAM DISTRIBUTION 15

3.1 CAREL jet distributors (SDPOEM00**) .........................................................15

3.2 Linear distributors for air pipes (DP***DR0) from CAREL .................15

3.3 CAREL ventilated steam distributors for rooms

(VSDU0A*, only models UR002...UR013) ....................................................16

3.4 Steam transport pipe .............................................................................................16

3.5 Condensate drain pipe .........................................................................................16

4. ELECTRICAL CONNECTIONS 18

4.1 Set up for power cables passageway ..........................................................18

4.2 Power supply cable connection .....................................................................18

4.3 Control board .............................................................................................................19

4.4 Steam production command signals ..........................................................20

4.5 Control with humidity probes ..........................................................................20

4.6 Alarm contact .............................................................................................................21

4.7 Final checks ..................................................................................................................21

5. SUPERVISOR NETWORK 22

5.1 RS 485 SUPERVISOR NETWORK .......................................................................22

6. PREPARING FOR OPERATION 22

6.1 Preliminary checks ...................................................................................................22

6.2 Removing the heating element centring spring

(only for three-phase models) ..........................................................................22

7. COMMISSIONING 23

7.1 Start ...................................................................................................................................23

7.2 Start-up sequence ...................................................................................................23

7.3 Autotest procedure .................................................................................................23

7.4 Shut down ....................................................................................................................24

7.5 User interface ..............................................................................................................24

7.6 Display .............................................................................................................................24

7.7 Keypad ............................................................................................................................25

7.8 Programming ..............................................................................................................25

7.9 Setting the set point (St) ......................................................................................25

7.10 Setting the adjusting and reading parameters; ....................................26

7.11 Modi cation of the con guration parameters ......................................26

7.12 Procedures ....................................................................................................................27

8. CONFIGURATION PARAMETERS 29

8.1 Parameter access and setting ...........................................................................29

8.2 Basic operation parameters ...............................................................................29

8.3 Auxiliary function parameters ..........................................................................29

8.4 Serial communication parameters ................................................................30

8.5 Control parameters .................................................................................................30

8.6 Measurement reading parameters ...............................................................30

9. ALARMS 31

9.1 Alarms table .................................................................................................................31

9.2 Autotest Retry procedure (Fault tolerance) ............................................33

9.3 Troubleshooting ......................................................................................................34

10. SPARE PARTS AND MAINTENANCE 35

10.1 Maintenance ...............................................................................................................39

10.2 Maintenance operations .....................................................................................39

10.3 Maintenance frequency .......................................................................................39

10.4 Maintenance of the cylinder-boiler ..............................................................39

10.5 Feeding/drain tempering solenoid valve .................................................41

10.6 Fill tray .............................................................................................................................41

10.7 Parts replacement ....................................................................................................41

10.8 Mechanical discharge of water in the cylinder .....................................43

10.9 Electrical connection of boiler heaters .......................................................44

11. WIRING DIAGRAMS 45

11.1 Wiring diagram UR002-UR004 single-phase 208 V ............................45

11.2 Wiring diagram UR002-UR004 single-phase 230 V ............................46

11.3 Wiring diagram UR006 single-phase 208 V ............................................47

11.4 Wiring diagram UR006 single-phase 230 V ............................................48

11.5 Wiring diagram UR006-UR010 (208-230-460-575 V) -

UR013 three-phase (230-460-575 V) ...........................................................49

11.6 Wiring diagram UR006-UR010-UR013 three-phase (400 V) .........50

11.7 Wiring diagram UR020-UR027 three-phase (208-230-460-575 V) .......51

11.8 Wiring diagram UR020-UR027 three-phase (400 V) ..........................52

11.9 Wiring diagram UR027 three-phase (230 V) ...........................................53

11.10 Wiring diagram UR040-UR053 three-phase (460-575 V) ................54

11.11 Wiring diagram UR040 - UR053 three-phase (400 V) .........................55

11.12 Wiring diagram UR053 three-phase (460 V) ...........................................56

11.13 Wiring diagram UR060 three-phase (575 V) ...........................................57

11.14 Wiring diagram UR060 (460-575 V) ...............................................................58

11.15 Wiring diagram UR060-UR080 three-phase (400 V) ..........................59

11.16 Wiring diagram UR080 three-phase (460-575 V) ................................60

12. GENERAL FEATURES AND MODELS 61

12.1 heaterSteam models and electrical features ..........................................61

12.2 Technical features ....................................................................................................62

12.3 Steam duct pipe models .....................................................................................62

12.4 Models of steam nozzles with concentrated jet ...................................62

12.5 Models of linear nozzles and typical installations ................................63

12.6 Table of parameter b1 ...........................................................................................64

12.7 Variables accessible in serial mode only ....................................................65

12.8 Production control via variables A52 and A53 .......................................66

13. ADVANCED FUNCTIONS 67

13.1 Operating principle .................................................................................................67

13.2 Regulation principles .............................................................................................67

13.3 Setting the alarm thresholds (type H or T control module) ..........68

13.4 Automatic total drain due to inactivity ......................................................68

13.5 User-adjustable duration of dilution drain ...............................................68

13.6 User-adjustable max. allowed no. of evaporation

cycles between 2 dilution drains ...................................................................69

13.7 Reduced  lls to restore water level after evaporation.......................69

13.8 PWM  lls after dilution and high-level/foam drains ...........................69

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

1. INTRODUCTION AND INSTALLATION

1.1 HeaterSteam (UR*)

Range of isothermal resistance humidi ers, equipped with LED display

for the control and distribution of steam.

Available models (identi ed by means of the code on the label, packaging

and on the technical data plate located inside the electrical cabinet):

• UR002, UR004, UR006, UR010, UR013 with steam production capacity

up to 13 kg/h (28,66 lb/h), hydraulic connections under the base of

the humidi er;

• UR020, UR027, UR040, UR053, UR060, UR080 with steam production

capacity from 20 to 80 kg/h (from 44.09 to 176.37 lb/h), hydraulic

connections next to the humidi er.

1.2 Dimensions and weights

Models UR002..UR013 Models UR020...UR080

B

A

C

B

A

C

Fig. 1.a

UR002…13 UR020…40 UR053…80

Size

mm (in)

A 365 (14,37) 690 (27,16) 876 (34,48)

B 275 (10.82) 445 (17,51) 445 (17,51)

C 712 (20,03) 888 (34,96) 888 (34,96)

Tab. 1.a

UR002…13 UR020…40 UR053…80

Weights

kg (lb)

packaged 31(68.3) 73(160.9) 98(216.0)

empty 26(57.3) 63(138.8) 87(191.8)

installed* 35(77.1) 97(213.8) 155(341.7)

Tab. 1.b

* in operating conditions,  lled with water.

1.3 When opening the packaging

• check the integrity of the humidi er upon delivery and notify to the

carrier immediately, in writing, any damage that can be attributed to

improper or careless transport;

• move the humidi er to the installation site before removing it from the

packaging, grasping the neck from beneath;

• open the cardboard box, remove the protective material and remove

the humidi er, keeping it upright at all times.

1.4 Positioning

• the unit is designed for wall mounting, suitable to support the weight

under operating conditions (see par. “Wall mounting”). The models

UR020*... UR080 * can be  oor installed;

• to ensure proper distribution of steam, place the humidi er next to the

steam distribution point;

• place the humidi er horizontally (using a plumb and level), observing

the minimum clearances (see Figure 1b) to allow for necessary

maintenance.

Caution: during operation, the external metal panels heat up, and

the back leaning against the wall can reach temperatures above

60 °C (140 °F).

Models UR002..UR013 Models UR020...UR080

≥200

(7.9”)

≥200 (7.9”)

≥200

(7.9”)

≥400 (15.7”)

≥700

(27.6”)

<0,5$

≥500

(19.7”)

≥200 (7.9”)

≥300

(11.8”)

≥700

(27.6”)

Fig. 1.b

1.5 Wall mounting

Mount the humidi er on the wall using the support bracket pre-attached

to the humidi er, using the screws kit supplied (for mounting dimensions

see table below).

instructions for fastening:

1. unscrew the wall bracket from the one attached to the humidi er;

2. secure the bracket to the wall (see Fig. 1.c), checking for plumb and

level; if the unit is mounted on a masonry wall, you can use the plastic

anchor plugs (Ø 8 mm, Ø 0.31in) and the screws (Ø 5 mm x L= 50

mm, Ø 0.19 in x L= 1.97 in) supplied;

3. hang the humidi er on the bracket using the pro le on the upper

edge of the unit’s rear.

4. lock the humidi er to the wall by means of the hole / holes found /

on the lower part of the rear panel of the machine.

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

W

X

Y

Z

..2*.. - ..13*..

..20*.. - ..40*..

X

Z

W

..53*.. - ..80*..

J

K

piano di foratura

drilling template

X

Y

Z

Y

Fig. 1.c

Seize mm (in) UR002-13 UR020-40 UR053-80

X 220 (8.7) 445 (17.5) 286 (11.3)

Y 591 (23.3) 728 (28.7) 731 (28.8)

Z 82 (3.2) 22.5 (0.9) 137 (5.4)

W - 400 (15.7) 416 (16.4)

J - - 235 (9.3)

K - - 201 (7.9)

Tab. 1.c

1.6 Removing the front panel

Models UR002…UR013:

1

2

3

4

5

Fig. 1.d

1. turn the oval plate with the CAREL logo until the ground screw head

can be seen;

2. loosen the screw with a screwdriver;

3. grab the sides of the panel, lift it about 20 mm (0.79 in), and detach it

from the protruding edges of the humidi er;

4. remove the panel by pulling it forward;

5. remove the protective  lm.

Models UR020...UR080:

1

3

2

4

5

Fig. 1.e

1. remove the screws on the top of the humidi er using a screwdriver;

2. grab the panel by lifting it from the top about 20 mm (0.79 in);

3. remove the panel by pulling it forward;

4. remove the protective  lm (on all external surfaces of the humidi er).

1.7 Mounting the front panel

Models UR002…UR013:

1

3

4

2

Fig. 1.f

1. turn the red oval plate with the CAREL logo so that the fastening hole

below is visible;

2. slide the panel on the frame (keeping it slightly raised and tilted) until

it stops on the rear edges;

3. fasten the ground screw using a screwdriver, ensuring its tightening;

4. turn the red oval plate with the CAREL logo so that the fastening hole

below is no longer visible;

Models UR020...UR080:

1

2

Fig. 1.g

1. slide the panel on the base, keeping it slightly tilted;

2. put it in vertical position and tighten the screws on the top cover

with a screwdriver.

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ENG

“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

Caution: in models UR020...UR080 open the electrical

compartment of the humidi er using the slotted lock.

Fig. 1.h

1.8 Material supplied with the appliance

Once the packaging opened and the front panel removed, check

if there is a:

screws and anchor

kit for wall mounting

only for models UR020...UR080: Code

FWHDCV0003 back  ow prevention valve

with connection tube

1.9 Technical data plate

Humidi ers can be identi ed by means of the technical plate placed on

the partition wall of the electrical cabinet.

MOD.

A

Vac

Hz

PH

kW

kg/h

IP

Date

Part No.

IP

Date

Part No.

Serial No.

Rev.

MADE IN ITALY

CAREL INDUSTRIES

Via dell'Industria, 11, 35020 Brugine

(Padova) Italy

Fig. 1.i

Note: tampering, removal, lack of the identi cation plate or other

does not allow the safe identi cation of the product and will

make any installation or maintenance operation to be performed di cult.

1.10 Hydraulic circuit

Models UR002 – UR013

31 2

5

4

7

8

6

9

10

16

17

12

11

19

18

15

14

Fig. 1.j

Models UR020 – UR080

16

1

5

7

12

19

17

14

13

9

18

6

Fig. 1.k

1 Anti-foaming sensor 11 Drain tube tempering (*)

2 Over ll diaphragm 12 Drain valve tempering (*)

3 Fill diaphragm 13 Inlet valve

4 Feeding tank 14 Drain pump

5

Electrodes for conductivity meas-

urement

15 Anti-adhesive  lm (**)

6 Equaliser pipe 16 Overtemperature sensors (PTC)

7 Feeding pipe 17 Heaters

8 Fill-up pipe 18

Water temperature sensor (NTC)

(**)

9 Level sensor 19 Thermal insulation cover (**)

10 Over ow pipe

(*) for the units equipped with it

(**) for full option modules only

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

1.11 Structure of models UR002 – UR0013

!

drain

x 1000

Steam

Drain

Fill

Alarm

PRG

reset

SEL

I

26

22

21

20

19

18

17

16

14

13

7

8

5

3

2

1

B

10

15

9

6

4

C

A27

11

12

Key:

1 Solid state relay (SSR)

2 Safety module (Motor protector, THP)

3 Fuse-holder base (F1, F2)

4 CONTACTOR

5 Transformer

6 Control card

7 Power cable terminal block

8 Pump fuse (F3)

9 Anti-jamming  lter (where provided)

10 Cable gland for power cables

11 Fan control board

12 Cable gland for auxiliary circuit

13 Cooling fan

14 ON/OFF switch

15 Drain

16 Electronic controller

17 NTC probe holder

18 Water heater tank

19 Warning label

20 Level sensor

A Green LED: normal operation

B yellow LED: loading

C red LED: safety level

21 Locking belt

22 Heating element(s)

23 Drain pump

24 Infeed valve

25 Drain tempering valve (where provided)

26 Feeding tank

27 Thermal switch (klixon) SSR

26

22

25

24

23

Fig. 1.l

11

ENG

“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

1.12 Structure of models UR020 – UR0080

drain

x 1000

Steam

Drain

Fill

Alarm

PRG

reset

SEL

I

25

1

24

23

22

21

20

19

18

17

15

14

13

11

10

9

8

7

6

5

4

3

16

12

2

26 27

Key:

1 Electronic controller

2 Thermal switch (klixon) SSR

3 Cooling fan

4 Solid state relay (SSR)

5 Heater fuse (where provided)

6 CONTACTOR

7 Safety module (Motor protector, THP)

8 NTC probe holder

9 Transformer

10 Control card

11 Fuse-holder base (F1, F2, F3)

12 Power cable terminal block

13 Anti-jamming  lter (where provided)

14 Power cable inlet

15 ON/OFF switch

16 Drain pump

17 Collection tray drain

18 Drain

19 Infeed valve

20 Drain tempering valve (where provided)

21 Drain tempering inlet (where provided)

22 Level sensor

23 Water heater tank

24 Drain pipe

25 Heating element(s)

26 Thermal switch (klixon) boiler

27 Anti-foaming sensor

28 Water  ll-up

29 Drain tempering water  ll-up (where provided)

29

28

18

17

Fig. 1.m

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

2. HYDRAULIC CONNECTIONS

Attention:before making the hydraulic connections disconnect

the humidi er from the power supply.

Models UR002..UR013 Models UR020...UR080

1

3

4

4 7

5

6

2

4

5

Fig. 2.a

HYDRAULIC CONNECTIONS:

1. install a manual valve upstream (to cut o the water supply);

2. connect the humidi er to the water supply. For UR002...UR013 models,

use a  exible pipe 3/4’’G connection. For UR020...UR080 models

connect the  exible pipe with the back ow prevention valve

(supplid - code FWHDCV0003), to avoid the water inside the

humidi er from making contact with the one in the mains;

3. install a mechanical  lter to retain any solid impurities (connect

before the inlet connection of the humidi er.

4. connect a section of pipe for draining (resistant to temperatures of

100 ° C (212 ° F)) and with a minimum internal diameter of 40 mm

(1.6 in) for models UR002-UR013 and 50 mm (2 in), for models UR020

UR080;

5. provide an open drain using a funnel to interrupt drain continuity;

6. connect a trap to prevent the return of odors;

7. for models UR020...UR080: connect a drain pipe from the drain pan

at the bottom of the humidi er (this can run into the funnel used for

draining).

8. for drain tempering versions, water temperature will be 60 °C (140 deg

F), so long as the temperature of the feed water is equal to or less than

25 °C (77 deg F) guaranteed.

Caution:

• once the installation is complete,  ush the supply pipe for about

30 minutes by carrying water directly in the drain and without

introducing it into the humidi er. This will eliminate any waste or

processing residues that could clog the inlet valve and/or cause foam

when boiling water;

• the drain pipe must run vertically downwards at least 30 cm (12 in)

( gure) to prevent the return of steam.

Set up for hydraulic connections:

Models UR002..UR013 Models UR020...UR080

B

A

D

B

C

Fig. 2.b Fig. 2.c

Key:

A Supply water inlet

B Drain water outlet

C bottom tank drain water outlet (only for models UR020-UR080)

D Drain tempering inlet (see explanation on chapter 12)

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

Hydraulic connections heights:

Drain / Fill

Models UR002…UR013 (view from below):

Fig. 2.d

mm (in)

D 75 (2.95) E 62 (2.44)

D’ 126 (4,96) E' 116 (4.57)

Water  ll Water  ll Water drain Water drain

Models UR020…UR080 (left side view):

L’

K

L

L”

I’

I

I”

J

Fig. 2.e

mm (in)

l 50 (1.96) L' 230 (9.0)

l' 120 (4.72) L” 54 (2.1)

l" 20 (0.78) J 132(5.2)

L 122 (4.8) K 571(22.5)

Water  ll Water  ll Water drain Water drain

Steam exhaust and condensate drain

Models UR002…UR013 (view from above):

A1

A2

A3

Fig. 2.f

seize mm (in) Models UR002-UR013

F 126.7 (5)

F' 224 (8.8)

G 137.9 (5.4)

G' 21.7 (0.85)

A1 Steam outlet

A2 Juncture for the steam distributor condensate drain pipe

A3 Fan head power cable passageway (ancillary)

Models UR020…UR080 (view from above):

B1

B2

PP

Fig. 2.g

seize mm (in) Models UR020...UR040 Models UR053-UR080

M 172 (6.8) 172 (6.8)

M' 31 (1.2) 52 (2.0)

N 273 (10.7) 260 (10.2)

N' --- 190 (7.4)

N" 46 (1.8) 52 (2.0)

P 60 (2.4) 60 (2.4)

B1 Set up for steam distributor condensate drain pipe

B2 Steam outlet

14

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

2.1 Supply water

The supply water for the electric resistance humidi er must not be

corrosive, must not emit bad odours, and must not contain too much

lime to avoid excessive deposits. The water, supplied from mains

of drinking water or demineralised water, must have the following

characteristics:

LIMIT VALUES FOR THE RESISTANCE HUMIDIFIERS WATERS

Resistances

Non-coated

Covered

with anti-ad-

hesive  lm

Min Max Min Max

Speci c conductivity at 20°C

/68°fH

σ20 - µS/cm 20 1500 1 1500

Total dissolved solids TDS – mg/l (1) (1) (1) (1)

Fixed residual at 180°C/ 356°fH TDS – mg/l (1) (1) (1) (1)

Hydrogen ion activity pH 6.5 8 6 8.5

Total hardness

TH– mg/l

CaCO3

0 (2) 400 0 400

Temporary hardness mg/l CaCO3 0 (3) 30 0 300

Chlorides ppm Cl = 20 = 50(4)

Iron + Manganese mg/l Fe+Mn = 0.2 = 0.2

Silica mg/l SIO2 = 20 = 20

Residual Chlorine mg/l Cl- = 0.2 = 0.2

Calcium sulphate mg/l CaSO4 = 100 = 100

Metallic impurities mg/l 0 0 0 0

Solvents, diluents, detergents,

lubricants

mg/l 0 0 0 0

Tab. 2.a

(1) Values depending on the speci c conductivity; in general: TDS ≈0,93 * σR, 20

°C; R180 ≈0,65 * σR , 20 °C;

(2) Not lower than 200% the content of chloride in mg/l Cl- ;

(3) Not lower than 300% the content of chloride in mg/l Cl- ;

(4) It could be necessary to intervene on the drain rate to avoid a concentration

in the boiling water higher than 300 mg/l Cl-.

Attention:treating the water with water softeners or

polyphosphates dispensers is not allowed; it allows for reduced

maintenance but favors the concentration of dissolved salts in the

water in the cylinder, leading to potential corrosion to the heating

elements and possible operation irregularities due to the formation of

foam. Should this be impossible to avoid, it requires dilution with

ordinary mains water in such a quantity as to guarantee at least 60% of

its initial hardness value, and not less than 5°f. Water treatment with

reverse osmosis demineralisers is allowed.

Not recommended:

1. the use of well water, industrial water or water from cooling circuits

and, in general, water which may be chemically or bacteriologically

contaminated;

2. the addition to the water of disinfectants or anticorrosion

compounds, as these may cause irritation.

Note: no relationship can be proven between water hardness

and conductivity; nonetheless, as an indication only, water with a

hardness of 40°f should have a conductivity of approximately 900-1000

mS/cm a 20 °C.

2.2 Drain water

• contains the same substances dissolved in the supply water, but in

larger amounts;

• it can reach a temperature of 100 °C (212° F);

• it is not toxic and can be drained in the white waters collection

system.

• for drain tempering versions, water temperature will be 60 °C (140 deg

F), so long as the temperature of the feed water is equal to or less than

25 °C (77 deg F) guaranteed.

Attention: completely demineralised water is aggressive. For

connection to a water system with fully demineralized water use

only installation items made of plastic resistant to chemicals (eg.

Polypropylene) or stainless steel.

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

3. STEAM DISTRIBUTION

3.1 CAREL jet distributors (SDPOEM00**)

They can be mounted either horizontally or vertically (steam exhaust

facing upwords).

See chapter 12 for distributors models.

Mounting instructions (see  gure):

1. drill a series of holes in the wall of the duct, using the drilling jig of

the distributor;

2. insert the distributor;

3. fasten the  ange of the distributor using 4 screws.

31,5

50 50

31,5

50

31,531,5

57,5

100

C

B

AA

B

D

Fig. 3.a

Key:

A. steam inlet

B. condensate drain

C.

steam outlet

The hole dimensions vary depending on the distributor model:

• model SDPOEM0000: hole to be drilled manually,

up to 30 mm (1.2 in) diameter;

• model SDPOEM0012: hole diameter 12 mm (0.5 in);

• model SDPOEM0022: hole diameter 22 mm (0.9 in);

D. drilling jig

Note: if you use distributors steam with an inner diameter of 30

mm (1.2 in) remove the 22 mm (0.9 in) steam inlet section from the steam

distributor.

3.2 Linear distributors for air ducts

(DP***DR0) from CAREL

Install far from any obstacle (curves, rami cation, section changes, grilles,

 lters, fans).

Minimum distance between distributor and obstacle: 1…1,5 m (3.3…4.9 ft).

Increase distance in case of:

1. increase in speed of the air in the duct;

2. turbulence decrease.

See paragraph 12.5 for installation examples.

Mounting instructions (see  gure):

• drill a series of holes in the wall of the pipe, using the drilling jig of the

distributor (found in the packaging of the distributor);

• insert the distributor with the steam outlet holes facing upwards;

• fasten the  ange of the distributor using 4 screws.

B

Y

X

A

X

°2

L

5

4

3

2

1

9

6

8

Fig. 3.b

Key:

1. L-shaped mounting bracket (where applicable)

2.  ange gasket

3. steam inlet (ØA)

4. condensate drain (ØB)

5. screw diameter (see instructions sheet that comes with the

distributor)

6. L = length (depending on the model of distributor, see paragraph

“Linear distributors” chap. 11)

7. tilt angle (about 2 °) for condensate drain

8. diameter of the hole in the wall (ØY)

Seize in mm (in)

linear distributors from CAREL

DP***D22R0 DP***D30R0 DP***D40R0

ØA 22 (0.9) 30 (1.2) 40 (1.6)

ØB 10 (0.4) 10 (0.4) 10 (0.4)

ØY 58 (2.3) 68 (2.7) 89 (3.5)

Ø 35 (1.4) 45 (1.8) 60 (2.4)

X 68 (2.7) 77 (3.0) 99 (3.9)

Tab. 3.a

Caution:

1. mount the distributor slightly tilted (at least 2°, to facilitate the

condensate discharge);

2. the L-shaped supports (see element 1 Fig. 3. b) is supplied with steam

distributors models from DP085* to DP025*. For shorter lengths the

bracket can be supplied as optional (code 18C478A088).

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

3.3 CAREL ventilated steam distributors for

rooms (VSDU0A*, only models UR002...

UR013)

Steam distributors for humidi ers up to 18 kg/h (39.7 lb/h). They can

be connected onto the humidi er or in a remote position (see  g. 3 c.)

These distributors have a power supply inside the electrical panel (24 Vac,

Terminals X1, X2).

A

B

C

D

E

F

G

Fig. 3.c

A > 0,5 m E > 0,5 m

B > 5 m F > 5 m

C > 2.1 m G > 1 m

D > 1 m

Caution: in order to achieve proper steam distribution observe

the distances indicated in the  g. above.

For the humidi ers larger than 18 kg/h, use ventilated steam distributors

code VRDXL00000 with 230 Vac power supply (maximum capacity 45

kg/h). The distributors are designed for installation in a remote position,

and require two steam hoses with a 30 mm diameter.

A > 0,9 m (>36”) E > 0,9 m (>36”)

B > 3 m (>120”) F > 3 m (>120”)

C > 1.8 m (>72”) G > 1.2 m (>48”)

D > 1.2 m (>48”)

3.4 Steam transport pipe

• use CAREL  exible hoses (max 4 m long, see section “Models of steam

conducting pipes paragraph 12.2);

• avoid the formation of pockets or traps (cause of condensate

accumulation)

• avoid choking the pipe with sharp bends or twists.

• Use metal clamps to fasten the ends of the pipe to the connections

on the humidi er and the steam distributor, so that they do not come

loose as a result of the temperature.

• avoid strains which include mechanical stress on the cylinder steam

outlet tailpiece

3.5 Condensate drain pipe

During the operation of the humidi er some of the steam can condense,

causing e ciency loss and noise (gurgling).

To drain the condensate connect to the base of the distributor a discharge

pipe with a water trap and a minimum slope of 5° (see  g.).

CAREL condensate drain pipes: code 1312353APG.

Caution: the condensate drain pipe trap must be  lled with water

prior to turning on the humidi er.

Examples of correct and incorrect installation of the steam conduct pipe

and of the condensate drain pipe:

>5°

D> 200mm

>5°

R> 300mm

H ≤ 2 m

Fig. 3.d

All the UR models

>20°

>5°

D>200mm

R>300mm

1

Fig. 3.e

Models UR002...UR013 (1): connection with  ll tray

>20°

>5°

D>200mm

R>300mm

1

Fig. 3.f

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

Models UE020...UR080 (1) extend the pipe inide the humidi er up

to the base tank.

NO

Fig. 3.g

All the UR models

SI

R>300mm

D> 200mm

NO

D> 200mm

Fig. 3.h

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

4. ELECTRICAL CONNECTIONS

4.1 Set up for power cables passageway

Models UR002-UR013

Exterior, view from below Interior, view from above

3

1

3

Fig. 4.a Fig. 4.b

Models UR20-UR80

Exterior, side view

1

3

2

Fig. 4.c

Key:

1. power supply cable inlet;

2. inlet (after drilling) for any other purpose;

3. probe cables inlet (after drilling).

4.2 Power supply cable connection

Before making the connections, ensure that the machine is disconnected

from the mains: set the master switch of the system and that of the

humidi er to OFF.

Attention: please note that the ON/OFF switch of the humidi er

cuts the power only to the electronic control, not the high

voltage, which remain powered.

Check that the voltage of the appliance’s power supply corresponds to

the value indicated on the data plate inside the electrical panel. Remove

the front panel as shown in chapter 1.

In order to insert the power cables and probes:

Models UR002-UR013

1. loosen the screws and remove the cover (A);

2. if necessary cut the top of the cone cable gland (B) and insert the

power cable;

3. connect the electrical cables to the terminal block, reinsert the cover

and fasten it with the screws;

To secure the probe cable:

4. remove the precut cable clamp (C) and loosen the screws;

5. insert the cable into the probe using the newly drilled hole: then

secure the cable with screws.

A

B

1

2

GND

L

N

3

Fig. 4.d Fig. 4.e

GND

L

N

C

4

GND

L

N

5

Fig. 4.f Fig. 4.g

Models UR020-UR080

1. Locate the grommet (A) on the right side of the appliance and pass

the power cable through it;

2. inside the electrical panel: unscrew the cable gland (B), connect the

wires to the terminal block and tighten the screws again to ensure

tightness.

GND

L1

L2

L3

B

A

Fig. 4.h

19

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

The power line to the humidi er must be  tted with a fused disconnect

protecting against short-circuits, to be mounted by the installer. The

table in chapter 12 shows the recommended cross-sections of the power

cable and the recommended sizes of the fuses; note, however, that this

data is purely indicative and, in the event of non-conformity with local

standards, the latter must prevail.

Note: in order to avoid unwanted interference, it is recommended

to keep the power cables separated from the signal ones from the

probes:

Caution: connect the yellow-green cable to the ground terminal

(GND).

4.3 Control board

The control board (S) is located inside the electrical panel, in the partition

wall.

UR002-UR013 UR020-UR080

S

Fig. 4.i Fig. 4.j

The auxiliary connections (probes, remote terminal, alarm), must be

made by introducing the external cables into the electrical panel. For this

purpose use the smaller fairlead on the base of the machine, passing the

cables through the raceway on the internal partition to the removable

screw terminals placed on the control board.

CONTROL BOARD

1I 2I 3I 4I 5I 6I

7I

8I

1K 2K 3K

1H 2H 3H

1E 2E 3E 4E 5E 6E

7E

8E

1J 2J 3J 4J

Main board

1G 2G

G H K I J

Key:

Terminal E: reserved;

Terminal G: reserved;

Terminal H: alarm contact

Terminal K: reserved

Terminals I: control signals

Terminals J: connection

with remote terminal or supervisory system

Fig. 4.k

terminal function electrical characteristics

1I humidity level probe signal input Input impedance:

50 k if set up for 0…20 mA or 4…10 mA

60 k if set up for 0…1 V or 0…10 V or 2…10 V

2I GND

3I ≈ 32 Vdc derived from rectifying of 24 Vac; max 250mA

4I 12 Vdc stabilised accuracy ± 5%; Imax=50 mA

5I

room probe signal input

or signal from external regulator

Input impedance:

50 k if set up for 0…20 mA or 4…10 mA

60 k if set up for 0…1 V or 0…10 V or 2…10 V

6I GND

7I

remote enabling Rmax=50 Ω; Vmax=24 Vdc; Imax=10 mAdc

8I

1H NO alarm contact

250 V; 8A with resistive load; 2A with indicative load2H common alarm contact

3H NC alarm contact

1G

Reserved

2G

1J ≈ 32 Vdc derived from rectifying of 24 Vac; max 250 mA

2J L +

standard RS485

3J L -

4J GND

1K

Reserved2K

3K

Tab. 4.a

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“heaterSteam” +0300075EN - rel. 1.2 - 29.09.2015

4.4 Steam production command signals

Attention: follow this sequence of steps in order to avoid

damaging the control board:

1. program the controller and turn it o ;

2. make the electrical connections;

3. switch the controller on.

The humidi er is  tted with solid-state relays, therefore its capacity

can vary from zero to 100% depending on the control requirements.

In addition, it can be connected by means of RS485 serial to a remote

supervisor. Depending on the type of signal used you can obtain

di erent types of enabling and/or management of the steam production

(ON/OFF or modulating). Production enabling is achieved by electrically

connecting the terminals 7I and 8I (jumper).

1. Steam production can be launched as follows:

HUMIDISTAT (ON/OFF):

• connect the inputs 4l and 5l (production command) to a humidistat;

• set parameter A0=0 to enable action ON/OFF

1I 2I 3I 4I 5I 6I

7I

8I

Fig. 4.l

Attention: prior to connecting the signal you must set the

parameters A0-A2-A6. See Paragraph 8.2.

HUMIDISTAT and REMOTE CONTACT (on/o )

• connect the inputs 4l and 5l (production command) to a humidistat;

• connect the inputs 7l, 8l (enabling) to a remote contact (e.g.: switch,

timer, ...);

• set parameter A0=0 to enable action ON/OFF

1I 2I 3I 4I 5I 6I

7I

8I

Fig. 4.m

Attention: prior to connecting the signal you must set the

parameters A0-A2-A6. See Paragraph 8.2.

2. Enabling and adjusting steam production as follows:

EXTERNAL PROPORTIONAL REGULATOR (modulating action)

• jumper connect inputs 7l, 8l;

• connect outputs 5l, 6l (production command) to an external regulator;

• set parameter A0=1 to enable the modulating action (see chapter 7)

and parameter A2 according to the signal chosen (0...1V, 0...10V, 2...10V,

0...20mA, 4...20mA).

1I 2I 3I 4I 5I 6I

7I

8I

OUT

REF

Fig. 4.n

Attention: prior to connecting the signal you must set the

parameters A0-A2-A6. See Paragraph 8.2.

EXTERNAL PROPORTIONAL REGULATOR and REMOTE CONTACT

(modulating action)

• connect inputs 7l and 8l to a remote contact (enabling);

• connect outputs 5l and 6l (production command) to an external

regulator;

• set parameter A0=1 to enable the modulating action (see chapter 7)

and parameter A2 according to the signal chosen (0...1V, 0...10V, 2...10V,

0...20mA, 4...20mA).

1I 2I 3I 4I 5I 6I

7I

8I

OUT

REF

Fig. 4.o

Attention: prior to connecting the signal you must set the

parameters A0-A2-A6. See Paragraph 8.2.

Note: in the industrial sector (CEI EN61000-6-2) signal cables that

come out of the appliance must not exceed 30 m in length: steam

production signal cable (terminals 5I, 6I), the remote ON/OFF digital input

(terminals 7I, 8I) and shielded cable for RS485 communication.

4.5 Control with humidity probes

The main control board, connected to an environment humidity

control probe, adjusts the steam production according to the humidity

measured. You can connect a second humidity probe on the outlet: in

this con guration, typical of air treatment plants, the main control board

continues to adjust the steam production according to humidity, which

depends however on the value of the relative humidity measured in the

outlet duct.

HP HLP

Remote Contact

Fig. 4.p

Key:

HP

Environment humidity regulating probe (intake/environ-

ment humidity probe)

HLP Humidity limit probe (outlet humidity probe)

Remote Contact Remote contact

Attention: prior to connecting the signal you must set the

parameters A0-A2-A6. See Paragraph 8.2.

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Carel heaterSteam UR Series User manual

Carel heaterSteam UR Series User manual

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